Solid-state image sensor, manufacturing method for solid-state image sensor, and camera

ABSTRACT

The solid-state image sensor in the present invention includes a plurality of light-receiving elements arranged in a light-receiving area, and a plurality of micro-lenses  7  corresponding to the light-receiving elements, and has a flattening film  8  formed on the plurality of the micro-lenses. At the center of the light-receiving area, micro-lenses  7  are placed in positions directly above the corresponding photodiodes  1 , and placed in positions which are progressively offset from the positions directly above the corresponding photodiodes  1 , towards the center of the light receiving area, as micro-lenses  7  are located farther from the center of the light-receiving area.

BACKGROUND OF THE INVENTION

(1) Field of the Invention

The present invention relates to a solid-state image sensor including micro-lenses for a plurality of light-receiving elements formed on a semiconductor substrate, and the manufacturing method thereof.

(2) Description of the Related Art

In recent years, the miniaturization of cameras is progressing along with the increase in the pixel count of solid-state image sensors.

With digital still cameras and camera-equipped mobile phones, the shortening of exit pupil distance is progressing following the miniaturization of cameras. At this point, exit pupil refers to the virtual image of a lens (or stop) as seen from the light-receiving area, and exit pupil distance refers to the distance between the light-receiving area and the lens (refer to FIG. 18).

FIG. 18 illustrates a cross-section diagram of the camera portion of a mobile phone. A lens 110 is installed on a frame 111 of the mobile phone, and a CCD image sensor 112 is provided in the interior of the mobile phone. The distance between the lens 110 and the CCD image sensor 112 is an exit pupil distance D. Although the incidence of light around the center of the light-receiving area is perpendicular, the periphery of the light-receiving area is limited to the incidence of, not perpendicular, but oblique light.

FIG. 1 is a cross-section diagram illustrating the physical relationship of light-receiving elements and micro-lenses in an existing solid-state image sensor for facilitating the shortening of exit pupil distance. The light rays from the light source in the diagram represent incident light from the lens. The left side of the diagram represents a cross-section of the central portion of the valid pixels making up the light-receiving area, and the right side represents a cross section of a peripheral portion of the valid pixels making up the light-receiving area. As shown on the left side of the diagram, an in-layer lens 3, a color filter 5, and a micro-lens 7 are formed directly above a light-receiving element 1, in the center of the light-receiving area. Whereas in the periphery of the light-receiving area, the in-layer lens 3, the color filter 5, and the micro-lens 7, are formed above the light-receiving element 1, offset towards the center of the light-receiving area, as shown in the right side of the diagram. In this manner, the existing solid-state image sensor forms a micro-lens in an offset position above a light-receiving element in a CCD image sensor light-receiving area, as a countermeasure for the shortening of exit pupil distance. With this, the improvement of light-collection rate for incident oblique light in the periphery of the light-receiving area is promoted.

Furthermore, in a solid-state image sensor disclosed in official publication of Japanese Laid-Open Patent Application No. 06-326284, a transparent film with a lower refractive index than micro-lens material is provided, and the deterioration of sensitivity upon lens stop release is minimized.

However, according to the existing technology mentioned above, the shortening of exit pupil distance in response to the sliming down of mobile phone cameras and digital still cameras is reaching its threshold. For example, if the shortening of exit pupil distance should progress further with regard to the configuration in FIG. 1, the light-receiving elements will no longer be able to perform light-collection as intended, as shown in FIG. 2, and the problem of shading arises due to lack of sensitivity in the periphery of the light-receiving area. In other words, from the center of an image, sensitivity deteriorates as the periphery is neared, and a deterioration of image quality arises in which darkening worsens towards the periphery of an image.

In addition, due to the shortening of exit pupil distance, it is necessary to carry out mask alignment with greater precision in the micro-lens formation process to form micro-lenses that are offset in the appropriate positions for the case in FIG. 2 as well, and position alignment is becoming difficult in terms of design and production.

Furthermore, although deterioration of sensitivity upon lens stop release is reduced in the solid-state image sensor disclosed in official publication of Japanese Laid-Open Patent Application No. 06-326284, the same problem exists with regard to the shortening of exit pupil distance.

SUMMARY OF THE INVENTION

In view of the aforementioned issue, the object of the present invention is to provide a solid-state image sensor, a manufacturing method thereof, and a camera, that makes possible the shortening of exit pupil distance, with low shading.

In order to resolve the aforementioned issues, the solid-state image sensor in the present invention is a solid-state image sensor including a plurality of light-receiving elements arranged in a light-receiving area, a plurality of micro-lenses corresponding to the light-receiving elements, and a flattening film formed on the plurality of micro-lenses, wherein the micro-lenses are placed in positions directly above the corresponding light-receiving elements at a center of the light-receiving area, and placed in positions which are progressively offset from the positions directly above the corresponding light-receiving elements towards the center, as micro-lenses are located farther from the center.

Here, it is possible to have a structure wherein a refractive index of the flattening film is less than the refractive index of the micro-lenses.

According to this structure, shortening of exit pupil distance while having low shading can be made possible through the combination of the incidence angle moderation by the flat film and the improvement of light-collection rate through offsetting.

Here, it is possible to have a structure wherein the micro-lenses are arranged in a matrix, adjoining each other without gaps, in row and column directions.

According to this structure, it is possible to further improve the light-collection rate of the micro-lens.

Here, it is possible to have a structure where the solid-state image sensor further includes in-layer lenses formed between the micro-lenses and the light-receiving elements, wherein the in-layer lenses are placed in positions directly above the corresponding light-receiving elements at the center of the light-receiving area, and placed in positions which are progressively offset from the positions directly above the corresponding light-receiving elements towards the center, as in-layer lenses are located farther from the center, and the offset of each micro-lens is greater than the offset of the corresponding in-layer lens.

According to this structure, shortening of exit pupil distance while having low shading can be made possible even in a structure having two or more layers of micro-lenses or two or more layers of in-layer lenses.

Here, it is possible to have a structure wherein at least one of a curvature and a thickness of the micro-lenses is greater than the curvature and the thickness of the in-layer lenses.

According to this structure, it is possible to further improve the light-collection rate of the micro-lens.

Here, it is possible to have a structure wherein the micro-lenses also serve as color filters.

According to this structure, the elimination of the color filter layer allows for just as much thin-filming of the solid-state image sensor.

Furthermore, the manufacturing method for the solid-state image sensor in the present invention has the same structuring effect as that mentioned above, for a camera provided with a solid-state image sensor.

According to the solid-state image sensor in the present invention, shortening of exit pupil distance while having low shading can be made possible through the combination of the incidence angle moderation by the flat film and the improvement of light-collection rate in the periphery of the light-receiving area through micro-lens offsetting.

FURTHER INFORMATION ABOUT TECHNICAL BACKGROUND TO THIS APPLICATION

The disclosure of Japanese Patent Application No. 2003-285555 filed on Aug. 4th, 2003, including specification, drawings and claims, is incorporated herein by reference in its entirety.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other objects, advantages and features of the invention will become apparent from the following description thereof taken in conjunction with the accompanying drawings that illustrate a specific embodiment of the invention.

In the Drawings:

FIG. 1 is a cross-section diagram of an existing solid-state image sensor.

FIG. 2 is a cross-section diagram of an existing solid-state image sensor.

FIG. 3 is a cross-section diagram of the solid-state image sensor in the first embodiment of the present invention.

FIG. 4 is a diagram illustrating the manufacturing process for the solid-state image sensor.

FIG. 5 is a diagram illustrating the manufacturing process (continuation) for the solid-state image sensor.

FIG. 6 is a diagram illustrating a variation of the manufacturing process for the solid-state image sensor.

FIG. 7 is a cross-section diagram of the solid-state image sensor in the second embodiment of the present invention.

FIG. 8 is a diagram illustrating the manufacturing process for the solid-state image sensor.

FIG. 9 is a diagram illustrating the manufacturing process (continuation) for the solid-state image sensor.

FIG. 10 is a diagram illustrating a variation of the manufacturing process for the solid-state image sensor.

FIG. 11 is a cross-section diagram of the solid-state image sensor in the third embodiment of the present invention.

FIG. 12 is a diagram illustrating the manufacturing process for the solid-state image sensor.

FIG. 13 is a diagram illustrating the manufacturing process (continuation) for the solid-state image sensor.

FIG. 14 is a diagram illustrating a variation of the manufacturing process for the solid-state image sensor.

FIG. 15 is a cross-section diagram of the solid-state image sensor in the fourth embodiment of the present invention.

FIG. 16 is a diagram illustrating the manufacturing process for the solid-state image sensor.

FIG. 17 is a diagram illustrating a variation of the manufacturing process for the solid-state image sensor.

FIG. 18 is a diagram illustrating the physical relationship of the camera lens and the CCD image sensor.

DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

(First Embodiment)

(Structure of the Solid-State Image Sensor)

FIG. 3 is a diagram representing a cross-section of the solid-state image sensor in the first embodiment of the present invention. This solid-state image sensor includes a light-receiving area in which light-receiving elements (photodiodes) are arranged two-dimensionally. The diagram represents a cross-section of two light-receiving elements in the center (diagram, left) and a cross-section of two light-receiving elements in the periphery (diagram, right) of the light-receiving area. Furthermore, the solid lines in the diagram schematically represent incident light from a light source (equivalent to the lens 110 shown in FIG. 18).

The solid-state image sensor in the same diagram is formed by stacking, a flattened transparent insulating film (protective film) 2 which is made out of material such as boron phosphate silicate glass (BPSG), an in-layer lens 3 having a high refractive index (n=1.5 to 2.0) and convex shape, an in-layer lens flat film 4 made out of an acrylic transparent resin, a color filter 5 made out of a color resist containing a dye or pigment, a transparent film 6 made out of an acrylic transparent resin, a micro-lens (also known as a top lens) 7, and a flattening film 8, in the order of mention, above a photodiode 1 formed on a silicon semiconductor substrate 10. It enables the shortening of exit pupil distance through the next 2 points, namely, (1) by having the flattening film 8 above the micro-lens 7, and (2) arranging the in-layer lens 3, color filter 5, and micro-lens 7, in positions that are offset towards the center, with the offset increasing with the proximity to the periphery of the light-receiving area. Moreover, the size of individual cells including a single photodiode is, for example, about 3 μm in length and width, or less, and the distance from the photodiode 1 to the bottom of the micro-lens 7 is in the area of about 3 to 5 μm.

To explain more specifically regarding (1), the flattening film 8 makes use of a material having a lower refractive index than the micro-lens 7 (n=1.6 to 1.7). For example, the material of the flattening film 8 is an acrylic resin with a refractive index of n=1.4 to 1.5. As such, although only incident light with a large incidence angle (assuming 0 degrees at the perpendicular direction to the light-receiving area) incidents in the periphery of the valid pixels within the light-receiving area, the incidence angle towards the micro-lens 7 can be moderated (reduced) by passing the incident light having a large incidence angle, through the flattening film 8, as shown on the right side of the diagram. Furthermore, the in-layer lens flat film 4 makes use of a material having a lower refractive index than the in-layer lens 3. For example, an acrylic resin with a refractive index of n=1.4 to 1.5.

To explain more specifically regarding (2), in the center of the valid pixels within the light-receiving area, the in-layer lens 3, the color filter 5, and the micro-lens 7, are formed in positions stacked directly above the photodiode 1, as shown on the left side of the diagram. In contrast, in the periphery of the valid pixels within the light-receiving area, the in-layer lens 3, the color filter 5, and the micro-lens 7 are formed offset towards the center, as shown on the right side of the diagram. This amount of offset, with regard to the individual in-layer lens 3, color filter 5, and micro-lens 7, is largest at the periphery, becomes smaller as the center is neared, and is “0” at the center. Furthermore, the offset increases with the higher layer, from the in-layer lens 3, the color filter 5, and micro-lens 7, in that order. With this offsetting, light-collection in the photodiode 1 can be carried out efficiently for the incident light with a large incidence angle in the periphery.

In addition, as another mechanism for improving the rate of light-collection in the solid-state image sensor in the diagram, aside from (1) and (2), (3) the two-dimensionally arranged micro-lenses 7 are formed adjacent to each other in columns and rows in such a way that no gaps are left in between. In addition, (4) each micro-lens 7 is formed with a greater curvature and thickness than the in-layer lens 3. In this manner, the improvement of the light-collection rate is promoted through the increase, as much as possible, of the diameter, and the increase of the curvature and the thickness of the micro-lens 7, combined with the aforementioned (1) and (2).

As explained so far, according to the solid-state image sensor in the present embodiment, it is possible to improve sensitivity in the periphery of the light-receiving area even for oblique light having larger incidence angles, by combining the incidence angle moderation through the flattening film 8 and the above-mentioned light-collection rate improvement. As a result, the shortening of exit pupil distance is made possible while suppressing shading.

(Manufacturing Method of the Solid-State Image Sensor)

FIG. 4(a) to (c) and FIG. 5(d) to (e) are diagrams illustrating cross-sections of the solid-state image sensor in the first embodiment, in manufacturing sequence. These manufacturing processes are explained in (11) to (15) below.

(11) As shown in FIG. 4(a), an in-layer lens 3 is formed, and an in-layer lens flat film 4 is formed on the in-layer lens 3. At this point, the in-layer lens 3 is formed by using a mask (first mask) in which the forming positions of the in-layer lens 3 are offset towards the center, with the offset increasing with the proximity to the periphery of the light-receiving area. The in-layer lens flat film 4 is formed by the application of an acrylic resin, for example.

(12) As shown in FIG. 4(b), a color filter is formed on top of the in-layer lens flat film 4. For example, in the case of the Bayer Array, which is typical of a primary color filter using the 3 colors, red, green, and blue (RGB), color resist application, exposure, and development is repeated for each of the colors R, G, and B. In this exposure, a mask (second mask) is used in which the forming positions of the color filter 5 are offset towards the center, with the offset increasing with the proximity to the periphery of the light-receiving area. Here, the offset of the second mask is larger than that of the first mask.

Accordingly, color filters corresponding to each photodiode 1 are formed.

Moreover, it is the same in the case where a complementary color filter, not a primary color filter, is formed. For example, in the complementary color checkered array that are typical as complementary color filters, color resist application, exposure, and development can just be repeated for the 4 colors, namely, the color green (G), and each of the complementary colors yellow (Ye), magenta (Mg), and cyan (Cy).

(13) As shown in FIG. 4(c), a transparent film 6 is formed on the color filter 5. This is done through the application of an acrylic resin, for example.

(14) As shown in FIG. 4(d), a micro-lens 7 is formed on the transparent film 6. To be specific, after forming a lens layer only on the micro-lens placement positions by applying, exposing and developing, 1 to 2 μm of a phenolic resin (refractive index n=1.5 to 1.7) as a resist, the curved surface of the lens is formed by thermal flow processing. In this exposure, a mask (third mask) is used in which the forming positions of the micro-lens 7 are offset towards the center, with the offset increasing with the proximity to the periphery of the light-receiving area. Here, the third mask has a larger offset than the second mask.

(15) As shown in FIG. 5(e), a flattening film 8 is formed on the micro-lens 7. To be specific, the flattening film 8 is formed by applying a 1 to 2 μm transparent film of acrylic resin (refractive index n=1.4 to 1.5).

The solid-state image sensor shown in FIG. 3 can be manufactured through the aforementioned manufacturing process.

(Variation of the Manufacturing Method)

Moreover, the processes in (15a) and (16) can be carried out in place of the aforementioned process (15), in the manufacturing method shown in FIG. 4 and FIG. 5. FIG. 6(e) to (f) is a diagram illustrating cross-sections for the processes in (15a) and (16), in this variation. Hereinafter, (15a) and (16) shall be explained.

(15a) As shown in FIG. 6(e), a flattening film 8 is formed on a micro-lens 7. To be specific, a 0.5 to 2 μm transparent film of acrylic resin (refractive index n=1.4 to 1.5) is applied.

(16) As shown in FIG. 6(f), film thickness is adjusted by etching back the applied transparent film. Moreover, (15a) and (16) can be repeated. With this, the film thickness of the flattening film 8 can be precisely adjusted.

In this manner, the solid-state image sensor shown in FIG. 3 can be manufactured, and the film thickness of the flattening film 8 can be accurately optimized, even through the present variation.

(Second Embodiment)

(Structure of the Solid-State Image Sensor)

FIG. 7 is a cross-section diagram of the solid-state image sensor in the second embodiment of the present invention. The structure in the same diagram is different in comparison to the structure in FIG. 3, in having the color filter 5 omitted, and having a micro-lens 7 a in place of the micro-lens 7. Hereinafter, explanation shall be made centering on the points of difference, with explanation on the points of similarity being omitted.

The micro-lens 7 a is different from the micro-lens 7 in that, being non-transparent, it also serves as a color filter.

According to this structure, as the micro-lens 7 a also serves as a color filter, the reduction of one color filter layer's worth of thickness furthers the thin-filming of the solid-state image sensor, in addition to enabling the shortening of exit pupil distance while also being able to limit shading as in the first embodiment. For example, in the case where the distance from the photodiode 1 to the bottom of the micro-lens 7 of the solid-state image sensor in the first embodiment is 3.0 to 5.5 μm, the solid-state image sensor in the second embodiment can be a slimmed down to a 2.0 to 4.5 μm thin-film. As a result, color mixing of light passing through color filters of adjacent photodiodes can be reduced, and image quality can be improved.

(Manufacturing Method Of The Solid-State Image Sensor)

FIG. 8(a) to (c), FIG. 9(d) to (f) are diagrams illustrating the manufacturing process of the solid-state image sensor. Such manufacturing process shall be explained in (21) to (26) below.

(21) As shown in FIG. 8(a), an in-layer lens 3 is formed, on which an in-layer lens flat film 4 is formed. As this process is the same as that in (11) mentioned previously, detailed explanation shall be omitted.

(22) As shown in FIG. 8(b), a color resist 7R is applied (0.5 to 2.0 μm) on the in-layer lens flat film 4. FIG. 8(b) shows the case where R (red) color resist is applied.

(23) The color resist 7R is only formed above the photodiodes corresponding to R (red) by exposing and developing the applied color resist 7R. In this exposure, a mask (second mask) is used in which the forming positions of the color resist are offset towards the center, with the offset increasing with the proximity to the periphery of the light-receiving area.

(24) As shown in FIG. 8(c), even with regard to G (green) and B (blue), a color resist is formed above the photodiodes corresponding to each color by carrying out the application, exposure, and development of the color resist in the same manner. Although only the 2 pixels for R and G are represented in FIG. 8(c), the color resist for each of the colors RGB are formed.

(25) As shown in FIG. 9(d), the shape of a micro-lens is formed on top of a color resist through the application, exposure, development, and thermal flow processing of a resist that can be subjected to thermal flow processing (e.g., a phenolic resin).

(26) As shown in FIG. 9(e), the lens shape can be transferred to the color resist by etching back. With this, a micro-lens 7 a is formed.

(27) As shown in FIG. 9(f), a flattening film 8 is formed on a micro-lens 7 a. As this process is the same as that in (15) mentioned previously, detailed explanation shall be omitted.

The solid-state image sensor shown in FIG. 7 can be manufactured through the aforementioned manufacturing process. Moreover, although the case of primary color filters is explained in the aforementioned process (23) and (24), a complementary color filter can also be formed in the same manner as previously explained in (12).

(Variation)

Moreover, processes in (27a) and (28) can also be carried out in place of the aforementioned process (27) in the manufacturing method shown in FIG. 8(a) to (c) and FIG. 9(d) to (f). FIG. 10(f) to (g) is a diagram illustrating cross-sections of the processes in (27a) and (28) in this variation. Hereinafter, explanation shall be made regarding (27a) and (28).

(27a) As shown in FIG. 10(f), a flattening film 8 is formed on a micro-lens 7 a. To be specific, a 0.5 to 2 μm transparent film of acrylic resin (refractive index n=1.4 to 1.5) is applied.

(28) As shown in FIG. 10(g), film thickness is adjusted by etching back the applied transparent film. Moreover, (27a) and (28) can be repeated. With this, the film thickness of the flattening film 8 can be precisely adjusted.

In this manner, the solid-state image sensor shown in FIG. 7 can be manufactured, and the film thickness of the flattening film 8 can be accurately optimized, even through the present variation.

(Third Embodiment)

(Structure of the Solid-State Image Sensor)

FIG. 11 is a cross-section diagram of the solid-state image sensor in the third embodiment of the present invention. The structure in the same diagram is different in comparison to the structure in FIG. 3 in having the color filter 5 omitted, and having an in-layer lens 3 a in place of the in-layer lens 3. Hereinafter, explanation shall be made centering on the points of difference, with explanation on the points of similarity being omitted.

The in-layer lens 3 a is different from the in-layer lens 3 in that, being non-transparent, it also serves as a color filter.

According to this structure, as the in-layer lens 3 a also serves as a color filter, the reduction of one color filter layer's worth of thickness furthers the thin-filming of the solid-state image sensor, in addition to enabling the shortening of exit pupil distance while also being able to limit shading as in the first embodiment. For example, in the case where the distance from the photodiode 1 to the bottom of the micro-lens 7 of the solid-state image sensor in the first embodiment is 3.0 to 5.5 μm, the solid-state image sensor in the third embodiment can be slimmed down to a 2.0 to 4.5 μm thin-film. As a result, color mixing of light passing through color filters of adjacent photodiodes can be reduced, and image quality can be improved. In addition, as the distance of the in-layer lens 3 which is a color filter and the photodiode 1 is short in the solid-state image sensor in the third embodiment compared to the solid-state image sensor in the second embodiment, color mixing can be further reduced.

(Manufacturing Method Of The Solid-State Image Sensor)

FIG. 12(a) to (d) and FIG. 13(a) to (h) are diagrams illustrating cross-sections of the solid-state image sensor, in manufacturing sequence. These manufacturing processes are explained in (31) to (39) below.

(31) As shown in FIG. 12(a), a color resist 3R is applied (0.5 to 2 μm) on the insulating film 2. The case where R (red) color resist is applied is shown in (a) of the same diagram.

(32) The color resist 3R is only formed above the photodiodes corresponding to R (red) by exposing and developing the applied color resist 3R. In this exposure, a mask (first mask) is used in which the forming positions of the color resist are offset towards the center, with the offset increasing with the proximity to the periphery of the light-receiving area.

(33) As shown in FIG. 12(b), even with regard to G (green) and B (blue), a color resist is formed above the photodiodes corresponding to each color by carrying out the application, exposure, and development of the color resist 3G and 3B in the same manner. Although only the 2 pixels for R and G are represented in FIG. 12(b), the color resist for each of the colors RGB are formed.

(34) As shown in FIG. 12(c), the in-layer lens shape is formed on top of a color resist through the application, exposure, development, and thermal flow processing of a resist that can be subjected to thermal flow processing (e.g., a phenolic resin). A mask having the same offset as the aforementioned first mask is also used in this exposure.

(35) As shown in FIG. 12(d), the in-layer lens shape can be transferred to the color resist by etching back. With this, an in-layer lens 3 a is formed.

(36) As shown in FIG. 13(e), an in-layer lens flat film 4 is formed on the in-layer lens 3 a.

(37) As shown in FIG. 13(f), micro-lens material is applied on the in-layer lens flat film 4.

(38) As shown in FIG. 13(g) a micro-lens 7 is formed by the exposure, development, and thermal flow processing of the applied micro-lens material. As the process in (38) is the same as that in (14) mentioned previously, detailed explanation shall be omitted.

(39) As shown in FIG. 13(h), a flattening film 8 is applied on the micro-lens. As this process is the same as that in (15), detailed explanation shall be omitted.

The solid-state image sensor shown in FIG. 11 can be manufactured through the manufacturing process mentioned above. Moreover, although the case of primary color filters is explained in the aforementioned processes in (31) to (33), a complementary color filter can also be formed in the same manner as previously explained in (12).

(Variation)

Moreover, processes in (39a) and (40) can also be carried out in place of the process in (39) mentioned previously, in the manufacturing method shown in FIG. 12(a) to (d) and FIG. 13(e) to (h). FIG. 14(h) to (i) is a diagram illustrating cross-sections of for the processes in (39a) and (40) in this variation. Hereinafter, explanation shall be made regarding (39a) and (40).

(39a) As shown in FIG. 14(h), a flattening film 8 is formed on a micro-lens 7. To be specific, a 0.5 to 2 μm transparent film of acrylic resin (refractive index n=1.4 to 1.5) is applied.

(40) As shown in FIG. 14(i), film thickness is adjusted by etching back the applied transparent film. Moreover, (39a) and (40) can be repeated. With this, the film thickness of the flattening film 8 can be precisely adjusted.

In this manner, the solid-state image sensor shown in FIG. 11 can be manufactured, and the film thickness of the flattening film 8 can be accurately optimized, even through the present variation.

(Fourth Embodiment)

(Structure of the Solid-State Image Sensor)

FIG. 15 is a cross-section diagram of the solid-state image sensor in the fourth embodiment of the present invention. In comparison to the structure in FIG. 11, the structure in the same diagram is different in having the in-layer lens flat film 4, the color filter 5, and the micro-lens 7 omitted, and having a flattening film 8 above an in-layer lens 3. Furthermore, as the flattening film 8 can be of the same material as the in-layer lens flat film 4, it can also be said that compared with the structure in FIG. 11, the solid-state image sensor in the same diagram assumes a structure in which the micro-lens 7 and the flattening film 8 are omitted.

According to this structure, in addition to enabling the shortening of exit pupil distance while also being able to limit shading as in the first embodiment, further thin-filming of the solid-state image sensor can be done due to the difference in having the single layer of the in-layer lens 3 a instead of the two layers of the micro-lens 7 and the in-layer lens 3.

(Manufacturing Method Of The Solid-State Image Sensor)

FIG. 16(a) to (e) is a diagram illustrating cross-sections of the solid-state image sensor, in manufacturing sequence. These manufacturing processes are explained in (41) to (46) below.

(41) As shown in FIG. 16(a), a color resist 3R is applied (0.5 to 2 μm) on the insulating film 2. As this process is the same as that in (31), detailed explanation shall be omitted.

(42) The color resist 3R is only formed above the photodiodes corresponding to R (red) by exposing and developing the applied color resist 3R. As this process is the same as that in (32), detailed explanation shall be omitted.

(43) As shown in FIG. 16(b), even with regard to G (green) and B (blue), a color resist is formed above the photodiodes corresponding to each color by carrying out the application, exposure, and development of the color resist 3G and 3B in the same manner. As this process is the same as that in (33), detailed explanation shall be omitted.

(44) As shown in FIG. 16(c), an in-layer lens shape is formed on top of a color resist. As this process is the same as that in (34), detailed explanation shall be omitted.

(45) As shown in FIG. 16(d), an in-layer lens 3 a is formed by transferring the shape of the formed in-layer lens to the color resist. As this process is the same as that in (35), detailed explanation shall be omitted.

(46) As shown in FIG. 16(e), a flattening film 8 is formed on the in-layer lens 3 a. As this process is the same as that in (15), detailed explanation shall be omitted.

The solid-state image sensor shown in FIG. 11 can be manufactured through the manufacturing process mentioned above. Moreover, although the case of primary color filters is explained in the aforementioned processes in (41) to (43), a complementary color filter can also be formed in the same manner as previously explained in (12).

(Variation)

Moreover, processes in (46a) and (47) can also be carried out in place of the process in (46) mentioned previously in the manufacturing method shown in FIG. 16(a) to (e). FIG. 17(e) to (f) is a diagram illustrating cross-sections for the processes in (46a) and (47) in this variation.

(46a) As shown in FIG. 17(e), a flattening film 8 is formed on an in-layer lens 3 a. To be specific, a 0.5 to 2 μm transparent film of acrylic resin (refractive index n=1.4 to 1.5) is applied.

(47) As shown in FIG. 17(f), film thickness is adjusted by etching back the applied transparent film. Moreover, (46a) and (47) can be repeated. With this, the film thickness of the flattening film 8 can be precisely adjusted.

In this manner, the solid-state image sensor shown in FIG. 11 can be manufactured, and the film thickness of the flattening film 8 can be accurately optimized, even through the present variation.

Furthermore, although primary color filters and complementary color filters are explained as examples of color filters, primary color filters can be used for solid-state image sensors that prioritize color tone, and the complementary color scheme can be used in a solid-state image sensor that prioritizes resolution and sensitivity.

Furthermore, although color resists that contain a dye, color resists that contain a pigment, and so on, exist as material for forming the color filter 5, any of such options is possible. Furthermore, a color filter can also be formed by dyeing a dyeable transparent resist.

Although only some exemplary embodiments of this invention have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention.

INDUSTRIAL APPLICABILITY

The present invention is suitable for a solid-state image sensor possessing a micro-lens on each of a plurality of light-receiving elements formed on a semiconductor substrate, a manufacturing method thereof, and a camera with such a solid-state image sensor, and is suitable, for example, for a CCD image sensor, an MOS image sensor, a digital still camera, a built-in mobile phone camera, a built-in notebook computer camera, a camera unit connected to an information processing device, and the like. 

1. A solid-state image sensor comprising a plurality of light-receiving elements arranged in a light-receiving area, a plurality of micro-lenses corresponding to the light-receiving elements, and a flattening film formed on the plurality of micro-lenses, wherein the micro-lenses are placed in positions directly above the corresponding light-receiving elements at a center of the light-receiving area, and placed in positions which are progressively offset from the positions directly above the corresponding light-receiving elements towards the center, as micro-lenses are located farther from the center.
 2. The solid-state image sensor according to claim 1, wherein the micro-lenses are arranged in a matrix, adjoining each other-without gaps, in row and column directions.
 3. The solid-state image sensor according to claim 1, wherein a refractive index of the flattening film is less than the refractive index of the micro-lenses.
 4. The solid-state image sensor according to claim 3, wherein the micro-lenses are arranged in a matrix, adjoining each other without gaps, in row and column directions.
 5. The solid-state image sensor according to claim 1, further comprising in-layer lenses formed between the micro-lenses and the light-receiving elements, wherein the in-layer lenses are placed in positions directly above the corresponding light-receiving elements at the center of the light-receiving area, and placed in positions which are progressively offset from the positions directly above the corresponding light-receiving elements towards the center, as in-layer lenses are located farther from the center, and the offset of each micro-lens is greater than the offset of the corresponding in-layer lens.
 6. The solid-state image sensor according to claim 5, wherein at least one of a curvature and a thickness of the micro-lenses is greater than the curvature and the thickness of the in-layer lenses.
 7. The solid-state image sensor according to claim 5, comprising color filters formed on top of the in-layer lenses, wherein the color filters are placed in positions directly above the corresponding light-receiving elements at the center of the light-receiving area, and placed in positions which are progressively offset from the positions directly above the corresponding light-receiving elements towards the center, as color filters are located farther from the center, and the offset of each color filter is less than the offset of the corresponding micro-lens, and greater than the offset of the corresponding in-layer lens.
 8. The solid-state image sensor according to claim 2, wherein the micro-lenses also serve as color filters.
 9. A manufacturing method for a solid-state image sensor including a plurality of light-receiving elements arranged in a light-receiving area, and a plurality of micro-lenses corresponding to the light-receiving elements, the method comprising: a micro-lens forming step of forming micro-lenses placed in positions directly above the corresponding light-receiving elements at a center of the light-receiving area, and placed in positions which are progressively offset from the positions directly above the corresponding light-receiving elements towards the center, as micro-lenses are located farther from the center; and a flattening film forming step of forming a flattening film on the formed micro-lenses.
 10. The manufacturing method according to claim 9, wherein the micro-lenses are formed in a matrix arrangement so as to adjoin each other without gaps, in row and column directions, in the micro-lens forming step.
 11. The manufacturing method according to claim 9, wherein flattening film with a refractive index that is less than the refractive index of the micro-lenses is formed in the flattening film forming step.
 12. The manufacturing method according to claim 11, wherein the micro-lenses are formed in a matrix arrangement so as to adjoin each other without gaps, in row and column directions, in the micro-lens forming step.
 13. The manufacturing method according to claim 9, further comprising an in-layer lens forming step of forming in-layer lenses above of the light-receiving elements, prior to the micro-lens forming step, wherein the in-layer lenses are placed in positions directly above the corresponding light-receiving elements at the center of the light-receiving area, and placed in positions which are progressively offset from the positions directly above the corresponding light-receiving elements towards the center, as in-layer lenses are located farther from the center, and the offset of each micro-lens is greater than the offset of the corresponding in-layer lens.
 14. The manufacturing method according to claim 13, wherein at least one of a curvature and a thickness of the micro-lenses is greater than the curvature and the thickness of the in-layer lenses.
 15. The manufacturing method according to claim 13, further comprising a color filter forming step of forming color filters on top of the in-layer lenses, prior to the micro-lens forming step.
 16. The manufacturing method according to claim 10, wherein micro-lenses which also serve as color filters are formed in the micro-lens forming step.
 17. A camera comprising a solid-state image sensor including a plurality of light-receiving elements arranged in a light-receiving area, and a plurality of micro-lenses corresponding to the light-receiving elements, wherein the solid-state image sensor includes a flattening film formed on the plurality of micro-lenses, and the micro-lenses are placed in positions directly above the corresponding light-receiving elements at a center of the light-receiving area, and placed in positions which are progressively offset from the positions directly above the corresponding light-receiving elements towards the center, as micro-lenses are located farther from the center. 